JP2006297757A - Manufacturing method of decorative film, decorative film and decorative article - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide the manufacturing method of a decorative film, which is used for a trial manufacture and on which a pattern consisting of arbitrary colors can be easily printed without employing a platemking process. <P>SOLUTION: In the manufacturing method of the decorative film having a transferring pattern layer through a peel ply on a base material sheet, the pattern layer is formed by piling up a colored layer printed with an inkjet printing equipment, and a hiding layer printed with a heat sensitive ribbon printing equipment. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a method for producing a decorative film for decorating a pattern to be printed, a decorative film, and a decorative product decorated with the decorative film.

  Conventionally, an in-mold molding method is known as one of methods for decorating a resin molding surface.

  In this in-mold molding method, a transfer film on which a pattern layer has been printed in advance is sandwiched in a mold at the time of injection molding, and the pattern is transferred to the surface of the molded product in the mold simultaneously with injection molding.

  As a method for producing a transfer film sandwiched in a mold, for example, a method is known in which a transparent release layer that is easier to peel from the film is provided on one side of a film substrate, and a pattern layer is formed thereon by gravure printing. (For example, refer to Patent Document 1).

  If such a transfer film is used, printing can be performed without using a solvent, so that decoration can be performed without polluting the environment. Further, if the pattern layer is formed by aluminum vapor deposition, a metal-plated texture can be easily formed on the resin surface.

In addition, according to the transfer method by in-mold molding, it is possible to print a pattern on the surface of a molded product having a complicated uneven surface such as a three-dimensional curved surface, which can be applied to mass production. There are advantages.
JP-A-55-105574

  As described above, a pattern layer is printed on the transfer film used for in-mold molding by gravure printing, and for example, cyan, magenta, yellow, and black plates are produced to print the pattern layer. By performing in-mold molding using a transfer film on which a pattern is printed using these plates, a decorative molded product having a high color tone reproducibility can be obtained.

  This type of decorative molded product is first prototyped to check whether it can be commercialized according to the image before mass production. If not, all the above-mentioned plates are wasted as well as the time spent on producing the plates.

  Therefore, a printing method using an ink jet printer has been proposed as means for printing a design on a transfer film without going through a plate making process.

  For example, if digital data created by DTP (desktop publishing) is printed directly on a transfer film using an ink jet method and in-mold molded using this transfer film, a pattern close to gravure printing can be transferred without going through the plate making process. Can be formed into a film.

  However, this ink-jet method can print high-definition for dark colors, but has a drawback that white printing cannot be performed.

  When printing a design on an object, a white presser layer is indispensable for preventing color loss, and a design with a desired color tone cannot be obtained unless a white presser layer can be formed on the transfer film. Under these circumstances, the color of the pattern that can be reproduced in the prototype is limited at present.

  The present invention has been made in consideration of the problems in manufacturing a small-sized decorative film such as the case of producing a prototype as described above, and can perform printing such as white press which cannot be printed by the ink jet method. The present invention provides a method for producing a decorative film, a decorative film, and a decorative product capable of printing a pattern of an arbitrary color in a small lot without going through a plate making process.

  1st form of the manufacturing method of the film for decorating which concerns on this invention is a manufacturing method of the film for decorating which has a design layer for transcription | transfer via a peeling layer on a base material sheet, Comprising: It forms by inkjet printing The colored layer and the concealing layer formed by thermal ribbon printing are overlapped to form a design layer. As an example of the decorative film, it is used for in-mold molding. The resulting transfer film is shown.

  In the present invention, the concealment layer is basically combined with the colored layer, and when the decorative film is added to the object to be decorated, it functions to conceal the background color of the object to be decorated. Although it is called a layer, it is not limited to complete concealment, and even if it allows transmission to some extent, it is called a concealment layer if it essentially has a concealment function. In addition, about the part in which the colored layer is not partially formed but the concealment layer is formed independently, the concealment layer can be functioned as a design layer.

  The 2nd form of the manufacturing method of the film for decorating which concerns on this invention is a manufacturing method of the film for decorating which has a design layer on a base material sheet, Comprising: The colored layer formed by inkjet printing, and a thermal ribbon The gist is to form a design layer by superimposing a concealing layer formed by printing. As an example of the decorative film, the design layer is directly on the base sheet without a release layer. After the decoration is formed, the decorative film in which the base sheet is integrated with the decorative product is shown.

  In the method for producing a decorative film according to the first and second embodiments, the pattern in the colored layer can be formed by inkjet printing, and the white presser in the concealing layer can be formed by thermal ribbon printing.

  In the present invention, the white presser foot is formed for the purpose of shining a design printed by an ink jet. However, if a white presser is directly visible by providing a portion that does not form a design, a white layer that cannot be printed by an ink jet. Can be used as

  Moreover, the pattern in a colored layer can be formed by inkjet printing, and the metallic color or metallic luster color in a concealing layer can be formed by thermal ribbon printing.

  Moreover, the pattern in a colored layer can be formed by inkjet printing, and the pearl color in a concealing layer can be formed by thermal ribbon printing.

  In addition, an ink receiving layer for landing the ink ejected from the ink jet head can be formed between the release layer and the design layer, and the release layer can also serve as the ink receiving layer. Good.

  Further, when the ink receiving layer is not formed, it is preferable to use a thermosetting ink as the ink for inkjet printing.

  For example, when a molded product is manufactured using a transfer film for surface transfer, a pattern by inkjet printing is formed on the release layer as a colored layer, and then a thermal ribbon printing device is used as a concealment layer from the pattern layer. A white presser will be formed. Also, when manufacturing a molded product using a transfer film for back transfer, a white presser is formed on the release layer as a concealing layer by thermal ribbon printing, and then ink jet printing is performed as a colored layer on the white presser. A pattern will be formed.

  For example, when manufacturing a molded product using a decorative film for front decoration, a pattern by ink jet printing is formed as a colored layer on a base sheet, and then a thermal ribbon is used as a concealing layer from the top of the pattern layer. A white presser will be formed by printing. Moreover, when manufacturing a molded article using a decorative film for back decoration, a white presser is formed on the release layer by thermal ribbon printing as a concealing layer, and then as a colored layer on the white presser. A pattern is formed by inkjet printing.

  In addition, in order to position the printing position by inkjet printing and the printing position by thermal ribbon printing, a colored layer or a concealing layer is formed on the base sheet and a positioning mark is printed, and inkjet printing is performed based on the positioning mark. Or if the positioning of the printing by thermal ribbon printing is performed, the printing layer formed by inkjet printing and the printing layer formed by thermal ribbon printing can be correctly superimposed.

  Moreover, when decorating with a sheet | seat, it is preferable to cut-out with a cutting plotter with respect to the decorating film in which the design layer was printed.

  Moreover, when the thickness of the base material sheet supplied to the ink jet printing apparatus is insufficient, the base material sheet is unwound from the base material sheet roll wound up in a roll shape, and on the opposite side of the printing surface in the base material sheet. A second sheet having a predetermined thickness can be laminated to increase the thickness and supplied to the ink jet printing process.

  In this case, if a half cut-out process is performed around the decorative layer where the design layer is formed on the base sheet in a range where the second sheet is not cut, it becomes easier to convey, and compared to the case of a single wafer. The decoration sheet can be easily taken out.

  The decorative film of the present invention is a decorative film having a pattern layer for transfer or decoration directly on a base material sheet through a release layer or directly on the base material sheet. The gist is that the pattern layer is formed in a state in which the formed colored layer and the concealing layer formed by thermal ribbon printing are overlapped.

  In the decorative film, a concealing layer is formed by thermal ribbon printing on a colored layer formed by ink jet printing, or a colored layer is formed by ink jet printing on a concealing layer formed by thermal ribbon printing. Can do.

  Moreover, the 1st form of the decorating product of this invention arrange | positions the decorating film manufactured with the said manufacturing method in a metal mold | die, and the film for decorating and the resin molded product are integrated by injecting resin. The main point is to be molded.

  Moreover, the 2nd form of the decorating product of this invention makes it a summary that the design layer is transcribe | transferred on the surface of the decorating target object by the film for decorating manufactured with said manufacturing method.

  Moreover, the 3rd form of the decorating product of this invention makes it a summary to have joined the decorating film as a decorating film manufactured with said manufacturing method integrally to the surface of the decorating object.

  According to the method for producing a decorative film of the present invention, a decorative film having a pattern of an arbitrary color that enables printing of a white presser or the like that could not be printed by an ink jet method, without undergoing a plate making process. Can be printed in small lots.

  According to the decorative film of the present invention, a pattern of any color can be formed on the film without going through a plate making process.

  According to the decorative product of the present invention, a design having an arbitrary color is a decorative product printed in a small lot without going through the plate making process.

  Hereinafter, the present invention will be described in detail based on the embodiments shown in the drawings.

  FIG. 1 is a process diagram showing a method for producing a decorative film according to the present invention. In the following description, a transfer film will be described as an example of a decorative film.

  As shown in FIG. 1A, when the transfer film 1 is manufactured, first, the release layer 4 is laminated on the base sheet 2 via the release layer 3.

  The material of the base sheet 2 is preferably PET (polyethylene terephthalate) having excellent heat resistance, but is not limited thereto, polycarbonate resin, polyamide resin, polyimide resin, polyester resin, acrylic resin, olefin resin, urethane. A single layer film selected from a resin, an acrylonitrile butadiene styrene resin, a vinyl chloride resin, or the like, or a laminated film or a copolymer film of two or more resins selected from the above can be used.

  Although the thickness of the base material sheet 2 can be 5 to 500 μm, it is preferable to use a material having a thickness of 25 to 75 μm in view of good handling properties, and 38 to 38 in view of good molding stability. It is preferable to use one having a thickness of 50 μm.

  The release layer 3 is a layer that has been surface-treated on the base sheet 2 in order to facilitate the peeling between the base sheet 2 and the release layer 4, and can be peeled only by the base sheet 2 and the release layer 4. The release layer 3 can be omitted. In addition, the material of the release layer 3 can be selected from the same materials as those described later as the material of the release layer 4.

  The release layer 4 is a layer located on the outermost side when the substrate sheet 2 is peeled off after transferring the design, and functions as a protective layer for the design.

  The release layer 4 is made of acrylic resin, nitrified cotton resin, polyurethane resin, chlorinated rubber resin, vinyl chloride-vinyl acetate copolymer resin, polyamide resin, polyester resin, epoxy resin, polycarbonate resin. Examples thereof include resins, olefin resins, acrylonitrile butadiene styrene resins, and the like.

  When the release layer 4 is required to have hardness, a photo-curing resin such as an ultraviolet curable resin, a radiation curable resin such as an electron beam curable resin, a thermosetting resin, or the like may be selected and used. In addition, the film thickness of the peeling layer 4 is preferably 0.5 to 50 μm.

  In FIG. 1B, an ink receiving layer 5 is laminated on the release layer 4.

  The components of the ink receiving layer 5 are composed of, for example, a binder and an inorganic filler.

  As the binder, hydrophilic gelatin, polyvinyl pyrrolidone, polyethylene oxide, polyacrylamide, polyvinyl alcohol, or the like can be used, and polyvinyl alcohol is particularly preferable in terms of the following.

  That is, polyvinyl alcohol has an interaction with inorganic fine particles, has a particularly high holding power with respect to the inorganic fine particles, and is a polymer having a relatively small humidity dependency such as hygroscopicity. Moreover, since the shrinkage stress during drying after coating is relatively small, there are few cracks.

  Specifically, the polyvinyl alcohol is a modified polyvinyl alcohol such as an anion-modified polyvinyl alcohol having a cationic group or an anionic group in addition to a normal polyvinyl alcohol obtained by hydrolysis of polyvinyl acetate. Is also included.

  On the other hand, as inorganic fillers, zeolite, light calcium carbonate, heavy calcium carbonate, magnesium carbonate, kaolin, talc, calcium sulfate, barium sulfate, zinc oxide, zinc sulfide, zinc carbonate, satin white, aluminum silicate, diatomaceous earth, Calcium silicate, magnesium silicate, silica, colloidal silica aluminum hydroxide, alumina, alumina hydrate, aluminosilicate, boehmite, suspect boehmite, etc. are mentioned. Silicate is preferred, and silica is particularly preferred.

  The particle size of the inorganic fine particles in the inorganic filler can be of any size, but the average particle size is preferably 4 μm or less, more preferably 0.1 μm or less in terms of good gloss and color development. is there.

  In addition, the lower limit of the particle size is not particularly limited, and in the case of the above-described silica (gas phase method), the average primary particle size is preferably 30 nm or less in order to obtain a structure having a large porosity, and the transparency of the coating is increased. For this purpose, the thickness is preferably 3 to 10 nm.

  When the binder and the inorganic filler are mixed, the ratio of the inorganic fine particles to the hydrophilic binder in the porous material layer as the water-based ink receiving layer is preferably 2 to 50 times by weight. If the weight ratio is 2 times or more, the porosity in the porous material layer is good, and a sufficient void volume can be obtained. As a result, excessive hydrophilic binder swells and closes the voids when printing by inkjet. This can be prevented.

  Moreover, when the weight ratio is 50 times or less, cracks are unlikely to occur when the porous material layer is applied as a thick film. Therefore, the ratio of the inorganic fine particles that is more preferable in terms of ensuring a sufficient void volume is 2.5 to 20 times in terms of weight ratio, and 5 to 15 times is most preferable considering the point of preventing cracking of the dried coating film.

  In addition, as a dispersion treatment method of the binder and the inorganic filler, a high-speed rotary disperser, a medium agitating disperser (ball mill, sand mill, etc.), an ultrasonic disperser, a colloid mill disperser, a roll mill disperser, a high pressure disperser, etc. However, it is preferable to use an ultrasonic disperser or a high-pressure disperser in that the dispersion can be efficiently performed.

  The ink receiving layer 5 may be applied by a known method such as a gravure coating method, a roll coating method, a rod bar coating method, an air knife coating method, a spray coating method, an extrusion coating method, a curtain coating method, or an extrusion coating method. A coating method can be adopted.

  When the ink receiving layer 5 is composed of two or more layers, it is preferable to continuously apply all the layers in-line in order to reduce the manufacturing cost.

  A pattern layer (colored layer) 6 is printed on the ink receiving layer 5 thus formed by an ink jet printing apparatus. The colored layer may be two or more layers.

  The inkjet method generally fixes the pattern by causing ink to land on and penetrate the print target, but even if the print target is not wettable like the transfer (resin) film of this embodiment, As shown in FIG. 1 (c), the ink ejected from the ink jet head drops on the ink receiving layer 5 and partially penetrates the ink receiving layer 5, so that the design can be printed with good fixability. Become. A solvent-based ink can be selected as the ink used in the inkjet printing apparatus.

  In this way, according to the ink jet printing method, for example, digital data created by DTP (desktop publish-ing) or the like is used as the pattern layer 6 including characters, symbols, patterns, coating patterns, etc. without going through the plate making process. Can be printed directly.

  However, even if printing is performed on the transparent substrate with only the above-described ink jet, color loss occurs, so that a white presser is necessary, but this white presser (white layer) cannot be printed by the ink jet method.

  Therefore, as shown in FIG. 1 (d), the white presser (hiding layer) 7 indispensable for the design layer 6 is printed using a thermal ribbon printing apparatus. Two or more concealing layers may be provided. The white presser 7 becomes a part of the above-described symbol layer 6 to form a symbol.

  The configuration of the thermal ribbon printing apparatus will be described in detail later. The thermal ribbon printing apparatus includes a ribbon cartridge in which an ink ribbon having a predetermined width is wound in a roll shape, and a carriage having a thermal head mounted in a direction perpendicular to the ink ribbon feeding direction. The ink is transferred by reciprocating, heating the thermal head corresponding to the image data, and pressing the heating head against the print target via the ink ribbon.

  Therefore, if a ribbon cartridge around which a white ink ribbon is wound is set and the color presser 7 is printed on the pattern layer 6, the white presser that is impossible with the ink jet can be made possible.

  As the white ink ribbon, a conventionally known one can be used, and specifically, a white sheet comprising a white pigment and a thermoplastic resin as a binder on a base sheet made of polyethylene terephthalate (PET). A paint is applied to a predetermined thickness.

  In this way, the white presser 7 that prevents color loss of the pattern layer 6 is formed.

  In the thermal ribbon, the white ink is formed on the base sheet through a release layer (hereinafter referred to as a thermal release layer). When the white ink is transferred, the transfer is performed with the thermal release layer. Is called. Therefore, when the white presser 7 is formed using the thermal ribbon printing apparatus, the upper surface of the white presser 7 is covered with the thermal release layer 8 as shown in FIG.

  FIG. 2 shows an apparatus configuration for printing the design layer 6 and the white presser 7.

  The printing apparatus 10 has an inkjet printing unit (inkjet printing apparatus) 11 and a thermal ribbon printing unit (thermal ribbon printing apparatus) 12 arranged in this order in the running direction (X direction) of the film 1a.

  In the following description, the film 1a means a film before the design layer and the white presser are printed, and is distinguished from the transfer film 1 after the design layer and the white presser are printed.

  The ink jet printing unit 11 includes an ink jet head (hereinafter abbreviated as a head) 11a that ejects ink, an ink cartridge (not shown) that supplies ink to the head 11a, and a carriage 11b that scans the head 11a. is doing.

  The head 11a may be of a continuous type in which an image is formed by continuously ejecting ink every predetermined time and deflecting the ejected ink droplets. An on-demand system that discharges ink correspondingly may be used.

  The ink ejection method includes a thermal method, an electrostatic actuator method, a piezo method, and the like, and any method may be used.

  On the other hand, the thermal ribbon printing unit 12 includes a thermal transfer ribbon 12a, a winding roll 12b that winds the ribbon, a thermal head 12c that includes a heating element, and a carriage 12d that scans the thermal head 12c. .

  In addition, transport mechanisms 13 and 14 for feeding the film 1a in the X direction and drivers 15 for controlling the movement of the carriages 11b and 12d are provided.

  The transport mechanism 13 includes a pair of feed rollers 13a and 13b disposed on the downstream side of the thermal head 12c, and the transport mechanism 14 includes a pair of feed rollers 14a and 14b disposed on the upstream side of the head 11a. Each feed roller is interlocked via a belt. One feed roller 13a is a drive roller driven by a motor 13c, and the rotation of the motor 13c is controlled by the driver 15.

  The film 1a is unwound from a supply roll (rolled film 1a cut into a predetermined width) 16 by the transport mechanisms 13 and 14 and supplied to the first platen 17 position.

  The carriage 11b scans the head 11a in the width direction of the film 1a under the control of the driver 15 similarly to the serial scan type ink jet printer, and two guides arranged in parallel to the width direction of the film 1a. The rails 11c and 11c are slid as guides.

  The carriage 11b is connected to an output shaft of a pulse control type motor (not shown) via a timing belt, and the head 11a mounted on the carriage 11b is attached to a film by controlling the amount and direction of rotation of the motor. The ink ejected from the head 11a can be deposited on the ink receiving layer 5 of the film 1a disposed with a gap of about 1 mm from the head 11a. It has become. Thereby, a desired design is printed.

  Next, the film 1 a on which the design layer 6 is printed is sent to the thermal ribbon printing unit 12.

  In the thermal ribbon printing unit 12, the white presser 7 is printed over the pattern layer 6 printed by inkjet.

  When printing the white presser 7, a ribbon cartridge in which the white thermal transfer ribbon 12a is wound in a roll shape is set on the carriage 12d, the carriage 12d is scanned in the width direction of the film 1a, and a thermal head provided in the carriage 12d. 12c is heated according to the printing range, the film 1a is sandwiched between the thermal head 12c and the second platen 18, and the white ink applied to the thermal transfer ribbon 12a is transferred to the film 1a.

  The white ink uses an ink composed of a thermoplastic resin and a colorant having a heat softening temperature that is melted by the heat of the thermal head and not melted by the heat at the time of transfer. In the figure, reference numeral 19 denotes a winding roll for winding the transfer film 1.

  FIG. 3 shows a state in which the transfer film 1 is viewed from the direction A in FIG.

  In the figure, a window frame-shaped pattern layer 6 is formed by ink jetting at a predetermined position of the transfer film 1, and the window frame-shaped white layer is also formed on the back side of the pattern layer 6 in a slightly wider range than the pattern layer 6. A presser 7 is formed. 6a is a blank character portion (ABC) formed on the symbol layer 6, and the white presser 7 can be seen through the blank character portion 6a. As a result, a white character ABC is formed on the symbol layer 6.

  The design layer 6 and the white presser 7 are overlapped on the basis of the positioning marks 20 arranged at the edges in the width direction of the transfer film 1.

  The positioning mark 20 is printed at the same time as the printing of the pattern layer 6 by inkjet, and is printed at a certain distance from the pattern layer 6 in a specific direction.

  A photocoupler 21 is provided on the moving path S of the positioning mark 20 with the transfer film 1 sandwiched between the upper and lower sides. When the photocoupler 21 detects the positioning mark 20, a signal is output, and this signal is received. The driver 15 controls the transport mechanisms 13 and 14 to send the symbol layer 6 to the position of the thermal head 12c and stop it.

Next, the carriage 12d is controlled, and the thermal head 12c is moved in the film width direction to move to a position corresponding to the design layer 6 to print one line (L ₁ ) of white ink over the width W. Next, while winding up the ink ribbon from which the white ink has been removed, the transfer film 1 is slightly fed in the X direction, and the next one line (L ₂ ) of white ink is printed over the width W. By repeating this operation, the white presser 7 is formed with a solid coating.

  In the above embodiment, the white presser has been described as an example. However, if the color of the thermal transfer ribbon 12a is changed to a ribbon of another color, for example, an aluminum-like grayish white ribbon, a metal color can be printed. A metallic feeling can be given to the color tone of the printed design.

  In addition, if a metallic (metallic gloss) ribbon is used, the same texture as the metal surface can be reproduced. If a pearl ribbon is used, a deep gloss can be given to the design. If a colored ribbon is used, a fluorescent pattern can be obtained.

  Furthermore, after the white presser 7 is printed, the above-described metal color, metallic color, or pearl color can also be printed on the white presser 7 again by thermal ribbon printing. Conversely, after printing a metal color, metallic color or pearl color, the white presser 7 can be printed thereon.

  Each of the above colors cannot be printed by inkjet, but can be easily printed by thermal ribbon printing.

  If printing is performed by combining the ink jet printing unit 11 and the thermal ribbon printing unit 12 in this way, almost all of the symbols printed on the transfer film 1 by gravure printing can be reproduced. Small molds can be easily prototyped by in-mold molding.

  The thermal ribbon printing unit 12 can also set each color ribbon of cyan, magenta, yellow, and black. A ribbon cartridge of the selected color is mounted on the carriage 12d and printed, for example, for one line. A color layer can be formed on one line by mounting a ribbon cartridge of the above color and printing on the same line and repeating this process a plurality of times.

  The color printed in this way is not as fine as an inkjet, but if such a color layer is superimposed on the back side of the inkjet design layer 6, the design layer 6 has a deep color. You can also.

  Further, if a portion where the design layer 6 is not formed is provided so that the metal color, metallic luster color, and pearl color can be seen directly, the design can be formed with these colors.

  FIG. 4 shows in-mold molding performed using the transfer film 1 obtained in the above process.

  In the figure, in-mold molding mainly comprises (a) a transfer film positioning step, (b) an injection molding step, and (c) a molded product taking-out step.

  The in-mold molding apparatus has a fixed mold 30 and a movable mold 31, and the transfer film 1 is passed between these molds. The transfer film 1 passing through both molds is arranged with the design layer 6 facing the fixed mold 30 side.

  The fixed mold 30 is formed with a sprue forming portion 30a for injecting a transparent resin toward the transfer film 1, and a nozzle of an injection molding device 32 is connected to the sprue forming portion 30a. When the fixed mold 30 and the movable mold 31 are closed, a cavity as a molten resin injection space is formed between both molds.

  Examples of the molten resin include general-purpose resins such as polystyrene resin, polyolefin resin, ABS resin, AS resin, and AN resin. Not limited to this, general-purpose engineering resins such as polyphenylene oxide / polystyrene resins, polycarbonate resins, polyacetal resins, acrylic resins, polycarbonate-modified polyphenylene ether resins, polybutylene terephthalate resins, polysulfone resins, polyphenylene sulfide resins, polyphenylene oxides Super engineering resins such as a series resin, a polyarylate resin, a polyetherimide resin, a polyimide resin, a liquid crystal polyester resin, and a polyallyl heat-resistant resin can also be used. A composite resin to which a reinforcing material such as glass fiber or inorganic filler is added is also included as the molten resin.

  The transfer film 1 is fed between the fixed mold 30 and the movable mold 31 having the above-described configuration, and positioning is performed. That is, the transparent resin that is injected into the cavity and molded and the pattern formed on the transfer film 1 are positioned so as to have a predetermined arrangement.

  In FIG. 4B, when the positioning of the transfer film 1 is finished, the fixed mold 30 and the movable mold 31 are closed, and transparent to the cavity formed between the opposed fixed mold 30 and the movable mold 31. Resin is injected.

  Next, after the injected transparent resin is cured, as shown in FIG. 4C, the fixed mold 30 and the movable mold 31 are opened, and the release layer 4 (see FIG. 1) is provided. The base sheet 2 is peeled off, and the molded product 33 remains on the fixed mold 30 side. The pattern layer 6 and the white pressing layer 7 are transferred to the resin molding surface of the molded product 33 and integrated with the molded product 33. Thereafter, the molded product 33 is removed from the fixed mold 30.

  FIG. 5 (a) shows a molded product surface-transferred by the in-mold molding.

  In the same figure, since the white presser 7 is formed in the lower layer of the design layer 6, when the transparent molded product 33 is viewed from the direction of the arrow B, no color loss occurs and the color tone of the design is faithfully reproduced. .

  On the other hand, as shown in FIG. 5B, there is also a back transfer method called back-in mold.

  In this case, since the design layer 6 is viewed through the transparent molded product 33, the white presser 7 is first printed on the release layer 4, and the design layer 6 is printed on the white presser 7.

  Therefore, the printing order is reversed between the inkjet printing and the thermal ribbon printing performed in the front transfer. Referring to FIG. 2, the film 1 a is conveyed in the direction opposite to the X direction, and after the white presser 7 is printed by the thermal ribbon printing unit 12, the design layer 6 is printed by the inkjet printing unit 11.

  Even if performing double-sided in-mold molding using the transfer film transferred to the front and the transfer film transferred back, a decorative product can be produced without any problem.

  Next, a case where transfer is performed on a single sheet using a transfer film finished to a certain size will be described.

  When the design layers 6 of the transfer film 1 are individually transferred one by one, unnecessary portions other than the transfer layer on which the design layer 6 is printed are cut in advance with scissors or a cutter. The work becomes complicated when there are many. In such a case, a cutting plotter can be used.

  This cutting plotter 22 (see FIG. 2) is arranged on the downstream side (in the film running direction) of the thermal ribbon printing unit 12.

  The transfer method using the cutting plotter 22 is usually performed by the following steps.

  First, the design layer 6 and the white presser 7 are printed on the base sheet by the same method as described above. Next, the periphery of the transfer layer of the transfer film 1 is cut by the cutting plotter 22. The design layer 6 is transferred to a transfer target using a single-sheet transfer sheet from which unnecessary portions are removed and only the transfer layer remains.

  In this embodiment, a cutting plotter 22 was used to cut the periphery of the transfer layer into a rectangular shape, and φ3 mm through holes were formed at the four corners of the cut transfer sheet.

  When the transfer sheet is placed in the molding die, the four positioning pins provided in the die are positioned in correspondence with the four through holes, and the transfer is performed by passing the positioning pins through the through holes. Set the sheet in place. If molding is performed in this manner, a decorative product with a pattern applied with high accuracy can be obtained.

  In this way, if the cutting plotter 22 is arranged on the transfer path of the transfer film 1, the process of removing the roll after printing the pattern and aligning the Thomson type again can be omitted. This makes it possible to complete the punching process necessary for the transfer of the image.

  In the above-described embodiment, the ink receiving layer 5 is laminated on the surface of the release layer 4 having poor water absorption, thereby allowing ink to be deposited from the ink jet. However, the release layer 4 should have ink acceptability. You can also.

  For example, if water absorption is imparted by mixing a water-absorbing filler, more preferably using a water-soluble resin for the release layer, the release layer 4 can function as an ink receiving layer, and the transfer film foil design can be improved. It can be simplified.

  In addition, a thermosetting resin ink having good compatibility with the release layer 4 can be used as an ink used for inkjet. If a thermosetting resin ink is used, even if the release layer 4 is not ink-receptive, it can be fixed to the release layer 4 by curing on the surface of the release layer 4. The thermosetting resin ink is composed of a colorant and a thermosetting binder made of, for example, epoxy or urethane.

  Further, in the above transfer film manufacturing method, if the transfer film 1 is too thin (for example, 25 μm or less), the transfer film 1 fed out from the supply roll 16 and taken up by the take-up roll 19 is inconvenient. Will occur.

  In such a case, it is preferable to overlap the second sheet to increase the thickness of the film 1a. Specifically, a PET film having a thickness of 125 μm is bonded as a second sheet to the back surface of the base sheet 2 in the film 1a having a thickness of 25 μm by thermal lamination. Incidentally, the peel strength of the laminated second sheet is 20 g / inch width.

  Thus, when it printed by the inkjet printing apparatus in the state laminated | stacked with the 2nd sheet | seat and printed by the thermal ribbon printing apparatus, both printability and the film conveyance property became favorable. After the design and the white presser are printed by the above method, the second sheet is peeled off, and in-mold molding is performed, the workability from printing to molding is improved.

  In addition, when the second sheet is laminated, if the above-described cutting plotter 22 is used, it is possible to remove only the transfer layer and efficiently leave only the transfer layer.

  Specifically, the cutting thickness by the cutting plotter 22 is set to 25 μm, and the transfer film 1 on which the second sheet is laminated is passed through the cutting plotter 22. In the cutting process by the cutting plotter 22, a 25 μm deep cut is made around the transfer layer and cut. As a result, the second sheet is not cut (half-cut), so that the transfer film is not divided as in the case of printing on a sheet, and the conveyance becomes easier, and the decorative sheet is more in comparison with the case of a sheet. Easy to take out.

  FIG. 6 (a) shows a cross section of a decorative layer that has been ink-jet printed with a water-based ink.

  The white presser 7 is formed on the surface of the molding resin 40 via the heat-sensitive release layer 8, and the ink receiving layer / release layer 4 ′ in which the pattern layer 6 is formed by inkjet is formed on the surface of the white presser 7. Yes. In this case, the heat-sensitive peeling layer 8 functions as an adhesive layer with the molding resin 40.

  FIG. 6B shows a cross section of a portion where the design layer 6 and the white presser 7 are not present, for example, a transparent portion, and the ink receiving layer / peeling layer 4 ′ functions as an adhesive layer with the molding resin 40.

  FIG. 6 (c) shows a cross section of a portion having the pattern layer 6 by ink jet and having no white presser 7. The ink receiving layer / peeling layer 4 'on which the pattern layer 6 is formed is formed of a molding resin 40. Functions as an adhesive layer.

  Moreover, Fig.7 (a) shows the cross section of the decorating layer inkjet-printed using the thermosetting ink.

  The white presser 7 is formed on the surface of the molding resin 40 via the heat-sensitive release layer 8, and the release layer 4 on which the design layer 6 is formed by inkjet is formed on the surface of the white presser 7. In this case, the heat-sensitive peeling layer 8 functions as an adhesive layer with the molding resin 40.

  FIG. 7B shows a cross section of a portion where the design layer 6 and the white presser 7 are not present, for example, a transparent portion, and the release layer 4 functions as an adhesive layer with the molding resin 40.

  FIG. 7 (c) shows a cross section of the portion having the pattern layer 6 by ink jet and where the white presser 7 does not exist. The pattern layer 6 by ink jet functions as an adhesive layer with the molding resin 40.

  In the above embodiment, the transfer film is described as an example of the decorative film. However, the present invention is not limited to this, and a decorative film other than the transfer film can be used. In this case, the decorative film is such that the design layer is formed directly on the base material sheet without a release layer, and after the decoration, the base material sheet is integrated with the decorative product. As with the transfer film, the decorative film used in this way can be printed with a pattern layer by ink jet and white press with a thermal ribbon.

  Although the thickness of the base material sheet for the decorative film can be 25 to 500 μm, it is preferable to use 50 to 300 μm in view of good handling properties, and good molding stability. Considering it, it is preferable to use a 100-250 micrometer thing.

  If such a base sheet is rolled and supplied to the printing apparatus shown in FIG. 2, a white-pressed pattern can be formed on the base sheet.

  Further, the method for producing a decorative film of the present invention is not limited to the case of producing a transfer film for in-mold molding, and a print object and a transfer film are laminated and passed between a heating and pressing roll and a receiving roll. It can be applied to the manufacture of a transfer film for thermal transfer in which a design is transferred to a printing object.

  Further, the decorative product of the present invention is not limited to the resin molded product shown in the above embodiment, but can also be applied to metal products, glass products, fabric products, paper products, and the like.

It is process drawing which shows the manufacturing method of the film for decorating which concerns on this invention. It is a block diagram of the printing apparatus for printing the design layer and white presser of a film for decorating. It is a top view of the film for decorating. It is process drawing of in-mold shaping | molding performed using the film for decorating. It is sectional drawing of the molded product in-mold-molded. It is sectional drawing of the decoration layer by which inkjet printing was carried out using water-based ink. It is sectional drawing of the decoration layer by which inkjet printing was carried out using the thermosetting ink.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Transfer film 2 Base material sheet 3 Release layer 4 Release layer 5 Ink receiving layer 6 Pattern layer (colored layer)
7 White presser (hidden layer)
8 Thermal Sensitive Release Layer 10 Printing Device 11 Inkjet Printing Unit 11a Head 11b Carriage 12 Thermal Ribbon Printing Unit 12a Thermal Transfer Ribbon 12b Winding Roll 12c Thermal Head 12d Carriage 13, 14 Conveying Mechanism 15 Driver 16 Supply Roll 17 First Platen 18 First Nino Platen 19 Winding Roll

Claims (19)

A method for producing a decorative film having a design layer for transfer via a release layer on a substrate sheet,
A method for producing a decorative film, wherein the pattern layer is formed by overlapping a colored layer formed by inkjet printing and a concealing layer formed by thermal ribbon printing. A method for producing a decorative film having a design layer on a substrate sheet,
A method for producing a decorative film, wherein the pattern layer is formed by overlapping a colored layer formed by inkjet printing and a concealing layer formed by thermal ribbon printing.   The manufacturing method of the film for decorating of Claim 1 or 2 which forms the design in the said colored layer by inkjet printing, and forms the white presser in the said concealment layer by thermal ribbon printing.   The manufacturing method of the film for decorating of Claim 1 or 2 which forms the pattern in the said colored layer by inkjet printing, and forms the metallic color or metallic luster color in the said concealing layer by thermal ribbon printing.   The manufacturing method of the film for decorating of Claim 1 or 2 which forms the design in the said colored layer by inkjet printing, and forms the pearl color in the said concealing layer by thermal ribbon printing.   The method for producing a decorative film according to claim 1, wherein an ink receiving layer for depositing ink ejected from an ink jet head is formed between the release layer and the design layer.   The method for producing a decorative film according to claim 1, wherein the release layer also serves as an ink receiving layer for landing ink ejected from an inkjet head.   The method for producing a decorative film according to any one of claims 1 to 5, wherein a thermosetting ink is used as the ink for inkjet printing.   After forming a pattern by inkjet printing as the colored layer on the release layer, forming a white presser by thermal ribbon printing as the concealing layer, or forming a white presser by thermal ribbon printing as the concealing layer, The manufacturing method of the film for decorating of Claim 1 which forms a pattern by inkjet printing as the said colored layer.   After forming a pattern by ink jet printing as the colored layer on the base sheet, and forming a white presser by thermal ribbon printing as the concealing layer, or forming a white presser by thermal ribbon printing as the concealing layer The manufacturing method of the film for decorating of Claim 2 which forms a pattern by inkjet printing as the said colored layer.   The colored layer formed by inkjet printing, forming the colored layer or the concealing layer on the base sheet and printing a positioning mark, positioning printing by ink jet printing or thermal ribbon printing based on the positioning mark. The manufacturing method of the film for decorating of any one of Claims 1-10 which superimposes and the concealment layer formed by thermal ribbon printing.   The manufacturing method of the film for decorating of any one of Claims 1-11 which performs a punching process with the cutting plotter with respect to the said film for decorating with which the design layer was printed.   Unwinding the base sheet from the base sheet roll wound in a roll, and laminating a second sheet having a predetermined thickness on the opposite side of the printing surface of the base sheet by laminating, The manufacturing method of the film for decorating of any one of Claims 1-12 supplied to an inkjet printing process.   The manufacturing method of the film for decorating of Claim 13 which performs a half cut punching process in the range which does not cut | disconnect said 2nd sheet | seat around the decorating layer in which the design layer was formed in the said base material sheet. It is a decorative film having a pattern layer for transfer or decoration directly on the base sheet through a release layer on the base sheet,
A decorative film, wherein the pattern layer is formed in a state in which a colored layer formed by inkjet printing and a concealing layer formed by thermal ribbon printing are overlapped.   16. The masking layer is formed by thermal ribbon printing on the colored layer formed by inkjet printing, or the colored layer is formed by inkjet printing on the masking layer formed by thermal ribbon printing. The film for decorating of description.   The decoration goods shape | molded by arrange | positioning the film for decorating manufactured with the manufacturing method of any one of Claims 1-11 in a metal mold | die, and injecting resin.   The decorative article by which the design layer was transcribe | transferred on the surface with the film for decorating manufactured with the manufacturing method of any one of Claims 1,3-9,11.   A decorative product obtained by integrally bonding a decorative film manufactured by the manufacturing method according to any one of claims 2 to 8, 10, and 11 to a surface.

Images